Sole with integrated mechanical device and method of assembling the same

ABSTRACT

A sole capable of being integrated in a boot or shoe and a method of assembling the same. The sole comprises an outsole, made of at least a first material, which defines an exterior lateral shape and an inner space for receiving a filling material and a housing for receiving a rigid mechanical device having protrusions that extend through corresponding openings of the sole. A wall surrounding the housing, made of the first material, has a minimum thickness of 20 mils. A portion of the wall is shared with a heel-section of the outsole. A seal plate is provided for, at least partly, covering the wall. the seal plate is for preventing the filling material from entering the housing. The filling material, once the sole is assembled, comprises a layer covering the seal plate and the sole conceals the mechanical device except for the protrusions.

TECHNICAL FIELD

The present invention relates to a shoe or boot sole and, more particularly, to a shoe or boot sole integrating a mechanical device.

BACKGROUND

Many solutions exist for preventing people from slipping when walking on ice or other slippery surfaces. For instance, mechanical devices have been developed with selectively extending spikes. Unfortunately, devices on the market that attempt to integrate such mechanical device in a sole while maintaining desired functionalities of a typical sole are ineffective or, at best, difficult to manufacture.

The present invention addresses this problem.

SUMMARY

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

A first aspect of the present invention is directed to a sole capable of being integrated in a boot or shoe. The sole comprises an outsole, made of at least a first material, that comprises an outer boundary defining an exterior lateral shape of the sole and an inner boundary defining an inner space of the outsole for receiving a filling material and a housing within the inner space for receiving a rigid mechanical device. The rigid mechanical device has a plurality of protrusions that extend from the outsole through a corresponding plurality of openings of the sole. A wall surrounding the housing, made of the first material, has a thickness of at least 20 mils (0.5 mm), preferably at least 40 mils (1 mm) and a portion of the wall is shared with the inner boundary along a heel-section of the outsole. A seal plate is provided for covering at least a portion of the wall surrounding the housing of the outsole. The seal plate is for preventing the filling material from entering the housing of the outsole. The filling material, once the sole is assembled, comprises a layer covering the seal plate. The sole, once assembled, conceals the mechanical device except for the plurality of protrusions.

Optionally, the plurality of openings may comprise a plurality of bottom openings from the outsole for allowing therethrough a plurality of retractable spike protrusions of the plurality of protrusions of the mechanical device and a lateral heel opening along the heel-section of the outsole for allowing an actuator protrusion of the plurality of protrusions of the mechanical device through the portion of the wall shared with the inner boundary of the outsole.

The first material may be one of natural rubber, synthetic rubber, polyurethane, thermoplastic or a blend thereof. The outsole may also be made of a second material different from the first material. The filling material may be a polymer (e.g., polyurethane) and the layer may have a thickness of at least 20 mils (0.5 mm). The layer may further provide electric isolation considering the mechanical device.

The seal plate may exemplarily be made of a polymer sheet non-porous to the filling material, of an alloy sheet non-porous to the filling material, of cardboard sheet non-porous to the filling material or of undulated cardboard sheet non-porous to the filling material.

The housing may further comprise inner intermediate walls.

A second aspect of the present invention is directed to a method of assembling a sole with a rigid integrated mechanical device. The sole is capable of being integrated in a boot or shoe. The method comprises providing a sole frame. The sole frame comprises an outsole, made of at least a first material. The outsole of the sole frame comprises an outer boundary defining an exterior lateral shape of the sole frame and an inner boundary defining an inner space of the outsole for receiving a filling material and a housing within the inner space for receiving a rigid mechanical device. The wall surrounding the housing, made of the first material, has a thickness of at least 20 mils (0.5 mm), preferably 40 mils (1 mm) and a portion of the wall is shared with the inner boundary along a heel-section of the outsole. The method also comprises inserting the rigid mechanical device within the housing of the outsole, the rigid mechanical device having a plurality of protrusions that extend from the outsole through a corresponding plurality of openings of the sole frame. The method then also comprises covering at least a portion of the wall surrounding the housing of the outsole with a seal plate and filling the outsole with the filling material. The filling material is prevented from entering the housing of the outsole by the seal plate, the filling material comprising a layer covering the seal plate, thereby concealing the mechanical device within the sole except for the plurality of protrusions.

Inserting the rigid mechanical device within the housing of the outsole may comprise, for instance, inserting an actuator protrusion of the plurality of protrusions of the mechanical device through a lateral heel opening along the heel-section of the outsole and inserting plurality of retractable spike protrusions of the plurality of protrusions of the mechanical device through a corresponding plurality of bottom openings from the outsole.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features and exemplary advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the appended drawings, in which:

FIG. 1 is an exploded perspective view of elements of an exemplary sole with an integrated mechanical device in accordance with the teachings of the present invention;

FIG. 2 is an assembled perspective view of the elements of the exemplary sole of FIG. 1;

FIG. 3 is an assembled perspective view of an exemplary sole with an integrated mechanical device in accordance with the teachings of the present invention; and

FIG. 4 is a flow chart of an exemplary method in accordance with the teachings of the present invention.

DETAILED DESCRIPTION

Reference is now made to the drawings in which FIG. 1 shows an exploded perspective view of elements 12 and 30 of an exemplary sole 1 with an integrated mechanical device 20, in accordance with the teachings of the present invention. FIG. 2 is concurrently referred to and shows an assembled perspective view of the elements 12 and 30 of the exemplary sole 1 of FIG. 1. FIG. 3 is also concurrently referred to and shows an assembled perspective view of the sole 1 with the integrated mechanical device 20 in accordance with the teachings of the present invention.

The sole 1 is capable of being integrated in a boot or shoe. The sole 1 comprises an outsole 40 made of at least a firstmaterial. The inside 50 of the outsole 40 comprises an outer boundary 52 defining an exterior lateral shape of the sole 1 and an inner boundary 54 defining an inner space of the inside 50 of the outsole 40 for receiving a filling material. The inside 50 of the outsole 40 also comprises a housing 56 within the inner space for receiving a rigid mechanical device 20. The rigid mechanical device 20 has a plurality of protrusions that extend from the inside 50 of the outsole 40 through a corresponding plurality of openings 58 of the sole 1. A wall 60 surrounding the housing 56 is made of the first material. In the example shown on FIG. 1, the wall 60 has a thickness of about 75 mils (1.75 mm). It is expected that a thickness of at least 20 mil (0.5 mm) is necessary to achieve the required structural effect on the sole 1, preferably 40 mils (1 mm). A portion 61 of the wall 60 is shared with the inner boundary 54 along a heel-section from the inside 50 of the outsole 40. The sole 1 also comprises a midsole 10 comprising a seal plate 12. The seal plate 12, in the assembled sole 1, covers at least a portion of the wall 60 surrounding the housing 56 of the inside 50 of the outsole 40. The seal plate 12 prevents the filling material from entering the housing 56 of the inside 50 of the outsole 40. The filling material, once the sole 1 is assembled, comprises a layer covering the seal plate 12. The sole 1, once assembled, conceals the mechanical device 20 except for the plurality of protrusions extending trough the openings 58. Skilled persons will readily understand that a certain amount of filling material may enter the housing 56 without affecting the present invention. That is, if filling material is allowed to enter the housing 56 (e.g., on purpose or not), it should not prevent proper mechanical function of the mechanical device 20 and should not unduly affect durability of the mechanical device 20 and, generally, of the sole 1 (e.g., by causing deformation or stress to the sole 1).

During manufacturing of the sole 1, the filling material expands and fills in the inside 50 of the outsole 40. In preferred embodiments, the filling material is limited in its expansion by a top plate of a filling apparatus (not shown), positioned over the seal plate 12. A top surface of the sole 1 is thereby formed when the filling material reaches the top plate. The top surface could also be partially or completely sculpted. In the depicted example of FIG. 3, the top surface of the sole 1 comprises a lip 11 therearound for better securing the boot or shoe thereover.

The design of the different structures of the inside 50 of the outsole 40 and the seal plate 12 allow formation of a seal above the mechanical device 20. The thickness of the seal plate 12 and the amount of filling material provides the rigid seal with a tensile strength. The tensile strength should be sufficient considering that the sole 1 is expected to be used in a boot or a shoe, e.g., for running or jumping therewith. The tensile strength considers expected movements of the sole 1 in use such that, for instance, the fore part of the sole may be put under higher pressure than the eel portion at certain times and vice-versa. A bound between the housing 56 and seal plate 12 (e.g., provided by the filling material and/or by an additional adhesive therebetween (not shown)) has to be sufficient to maintain the required tensile strength of the midsole 10. Skilled person will also readily acknowledge that the filling material also contributes to the tensile strength and to distribution of the different forces within the sole 1 when in use.

Persons skilled in the art will readily recognize that the number of protrusions 58 as well as the shape of the rigid mechanical device 20 may be changed without affecting the teachings of the present invention.

In the depicted exemplary embodiment, the plurality of openings 58 comprise a plurality of bottom openings 58 from the inside 50 of the outsole 40 through the outsole 40 for allowing therethrough a plurality of retractable spike protrusions of the plurality of protrusions of the mechanical device 20 and a lateral heel opening 58′ along the heel-section from the inside 50 of the outsole 40 for allowing an actuator protrusion 22 of the plurality of protrusions of the mechanical device 20 through the portion 61 of the wall 60 shared with the inner boundary 54 of the inside 50 of the outsole 40. In the depicted example of FIG. 1, the portion 61 of the wall 60 completely surrounds the actuator protrusion 22 in the first material. The portion 61 thereby maintains the minimal thickness of other portions of the wall 60.

The first material may be one of natural rubber, synthetic rubber, polyurethane, thermoplastic or a blend thereof. The outsole may also be made of at least a second material different from the first material. For instance, the second material may be of different color, texture and/or composition. Specifically, the second material may be a softer polymer used for certain portions of the outsole 40 not expected to be in contact with the ground. Conversely, the second material may be a harder polymer used for certain portions of the outsole 40 expected to be in contact with the ground.

In the depicted exemplary embodiment, the filling material is a polymer (e.g., polyurethane) and the layer over the seal plate 12 has a thickness of at least 20 mils (0.5 mm). The layer provides electric isolation considering characteristics of the mechanical device 20. In preferred embodiments, the seal plate 12 is non-porous to the filling material. The seal plate 12 prevents the filling material from entering the housing 56 in such a way that would change the mechanical properties of the sole 1.

For instance, the seal plate 12 may be made of different materials such as a fabric sheet or polymer sheet or one or more materials presenting the required mechanical properties. For instance, the seal plate 12 may be made of an alloy sheet non-porous to the filling material, of cardboard sheet non-porous to the filling material, of undulated cardboard sheet non-porous to the filling material, etc.

The housing 56 may further comprise inner intermediate walls 64, which may further support the mechanical device 20 within the housing 56.

FIG. 4 shows a flow chart of an exemplary method 4000 in accordance with the teachings of the present invention. The method 4000 is for assembling a sole with a rigid integrated mechanical device. The sole is capable of being integrated in a boot or shoe. The method 4000 comprises providing 4010 a sole frame that comprises an outsole made of at least a first material. The outsole comprises an outer boundary defining an exterior lateral shape of the sole frame and an inner boundary defining an inner space of the outsole for receiving a filling material and a housing within the inner space for receiving a rigid mechanical device. A wall surrounding the housing, made of the first material, has a thickness of at least 20 mils (0.5 mm), preferably 40 mils (1 mm). A portion of the wall is shared with the inner boundary along a heel-section of the outsole.

The method 4000 also comprises inserting 4020 the rigid mechanical device within the housing of the outsole. The rigid mechanical device has a plurality of protrusions that extend from the outsole through a corresponding plurality of openings of the sole frame.

In some embodiments, inserting 4020 the rigid mechanical device within the housing of the outsole may optionally comprise inserting an actuator protrusion of the plurality of protrusions of the mechanical device through a lateral heel opening along the heel-section of the outsole and inserting plurality of retractable spike protrusions of the plurality of protrusions of the mechanical device through a corresponding plurality of bottom openings from the outsole.

The method 4000 then follows with covering 4030 at least a portion of the wall surrounding the housing of the outsole with a seal plate before filling the midsole with the filling material. The filling material is prevented from entering the housing of the outsole by the seal plate. The filling material comprises a layer covering the seal plate, thereby concealing the mechanical device within the sole except for the plurality of protrusions.

In some embodiments, once the mechanical device is inserted 4020 in the outsole and covered 4030 by the seal plate, the outsole is put on a bottom plate of a filling apparatus (not shown). In this example, one or more side rings are then sealingly closed (sideways or vertically) on the outsole. The filling material is then put in the outsole. A top plate is then positioned over the outsole while the filling material expands (e.g., typically between 2 and 4 minutes). When the filling material expands, it fills the outsole and also expands towards the top plate, over the seal plate. A top surface of the sole is thereby formed when the filling material reaches the top plate. The top surface of the sole is shaped (e.g., by the top late) for receiving and bounding a shoe or boot thereon.

The description of the present invention has been presented for purposes of illustration but is not intended to be exhaustive or limited to the disclosed embodiments. Many modifications and variations will be apparent to those of ordinary skill in the art. The drawings are not necessarily drawn to scale. The embodiments were chosen to explain the principles of the invention and its practical applications and to enable others of ordinary skill in the art to understand the invention in order to implement various embodiments with various modifications as might be suited to other contemplated uses. 

What is claimed is:
 1. A sole capable of being integrated in a boot or shoe, the sole comprising: an outsole made of at least a first material, comprising: an outer boundary defining an exterior lateral shape of the sole and an inner boundary defining an inner space of the midsole for receiving a filling material; and a housing within the inner space for receiving a rigid mechanical device, the rigid mechanical device having a plurality of protrusions that extend from the midsole through a corresponding plurality of openings of the sole, wherein a wall surrounding the housing, made of the first material, has a thickness of at least 20 mils (0.5 mm) and wherein a portion of the wall is shared with the inner boundary along a heel-section of the midsole; and a midsole comprising a seal plate, covering at least a portion of the wall surrounding the housing of the outsole, for preventing the filling material from entering the housing of the outsole, the filling material, once the sole is assembled, comprising a layer covering the seal plate; wherein the sole, once assembled, conceals the mechanical device except for the plurality of protrusions.
 2. The sole of claim 1, wherein the plurality of openings comprises: a plurality of bottom openings from the outsole for allowing therethrough a plurality of retractable spike protrusions of the plurality of protrusions of the mechanical device; and a lateral heel opening along the heel-section of the outsole for allowing an actuator protrusion of the plurality of protrusions of the mechanical device through the portion of the wall shared with the inner boundary of the outsole.
 3. The sole of claim 1, wherein the first material is one of natural rubber, synthetic rubber, polyurethane, thermoplastic or a blend thereof.
 4. The sole of claim 3, wherein the outsole is made of at least a second material different from the first material.
 5. The sole of claim 1, wherein the filling material is a polymer and the layer has a thickness of at least 20 mils (0.5 mm).
 6. The sole of claim 6, wherein the layer provides electric isolation considering the mechanical device.
 7. The sole of claim 6, wherein the polymer is a polyurethane.
 8. The sole of claim 1, wherein the seal plate is a polymer sheet non-porous to the filling material.
 9. The sole of claim 1, wherein the seal plate is an alloy sheet non-porous to the filling material.
 10. The sole of claim 1, wherein the seal plate is made of cardboard sheet non-porous to the filling material.
 11. The sole of claim 10, wherein the seal plate is made of undulated cardboard sheet non-porous to the filling material.
 12. The sole of claim 1, wherein the housing further comprises inner intermediate walls.
 13. A method of assembling a sole with a rigid integrated mechanical device, the sole being capable of being integrated in a boot or shoe, the method comprising: providing a sole frame comprising: an outsole made of at least a first material, comprising: an outer boundary defining an exterior lateral shape of the sole frame and an inner boundary defining an inner space of the outsole for receiving a filling material; and a housing within the inner space for receiving a rigid mechanical device, wherein a wall surrounding the housing, made of the first material, has a thickness of at least 20 mils (0.5 mm) and wherein a portion of the wall is shared with the inner boundary along a heel-section of the outsole; and inserting the rigid mechanical device within the housing of the outsole, the rigid mechanical device having a plurality of protrusions that extend from the outsole through a corresponding plurality of openings of the sole frame; covering at least a portion of the wall surrounding the housing of the outsole with a seal plate; and filling the outsole with the filling material, wherein the filling material is prevented from entering the housing of the outsole by the seal plate, the filling material comprising a layer covering the seal plate, thereby concealing the mechanical device within the sole except for the plurality of protrusions.
 14. The method of claim 13, wherein inserting the rigid mechanical device within the housing of the outsole comprises: inserting an actuator protrusion of the plurality of protrusions of the mechanical device through a lateral heel opening along the heel-section of the outsole; and inserting plurality of retractable spike protrusions of the plurality of protrusions of the mechanical device through a corresponding plurality of bottom openings from the outsole.
 15. The method of claim 13, wherein the first material is one of natural rubber, synthetic rubber, polyurethane, thermoplastic or a blend thereof.
 16. The method of claim 15, wherein the outsole is made of at least a second material different from the first material.
 17. The method of claim 13, wherein the filling material is a polymer and the layer has a thickness of at least 20 mils (0.5 mm).
 18. The method of claim 13, wherein the layer provides electric isolation considering the mechanical device.
 19. The method of claim 13, wherein the seal plate is a polymer sheet non-porous to the filling material, an alloy sheet non-porous to the filling material, is made of cardboard sheet non-porous to the filling material or is made of undulated cardboard sheet non-porous to the filling material.
 20. The method of claim 13, wherein the housing further comprises inner intermediate walls. 